Grout block

ABSTRACT

A building block is described, which has a recessed grout trough at its mid-perimeter, top, bottom and ends. It has a hollow core and beveled edges. After each row of block has been positioned, a liquid grout is poured into the grout trough at the end of each block and flows downwardly and into the bottom trough, before setting up.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] NOT APPLICABLE

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] NOT APPLICABLE

INCORPORATED-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

[0003] NOT APPLICABLE

BACKGROUND OF THE INVENTION

[0004] (1) Field of the Invention

[0005] This invention is directed to a masonry building block havingrecessed troughs to contain liquid grout.

[0006] Beginning with the earliest civilizations, men have beenconstructing walls and other structures of masonry blocks. And throughthe centuries the technology and techniques have little changed.Initially, large blocks were shaped out of stone and stacked on oneanother. Their size and weight were sufficient to maintain them in theirstacked assembly. Later, bricks were formed of sun-dried clay. Beingsmaller and lighter than stone blocks, bricks could not be simplystacked. So a cementitious mortar was used between the bricks tomaintain them in their stacked assembly. In more recent years, cinderblock has been widely used. Like brick, cinder block requires mortar.The technique is the same. An initial row of brick or block is laid on astable surface with mortar applied by trowel between adjacent ends and alayer of mortar is applied by trowel to the top surface of that row;then the next row is laid in a similar manner on top the initial row.Each individual brick is positioned so that the vertical mortar jointextends directly above the middle of the brick in the row beneath.Subsequent rows are laid in a similar manner as the wall ascends.

[0007] One advantage of brick and cinder block over larger stone blockis that being smaller and lighter, they can be more easily lifted andpositioned by the masons building the wall. One disadvantage is themortar joint. It breaks up the monolithic appearance of the wall and isunaesthetic. Another disadvantage is that a high degree of skill isrequired in laying the brick or block and applying the mortar. It mustbe applied evenly and consistently. For reasons of economy, it must alsobe applied as quickly as possible. Needing skilled masons to lay wallsor other such structures of brick and block, adds greatly to the cost ofsuch construction. Furthermore, the possibility of mortar which isimproperly mixed or applied, creates the risk of a structure that is notsafe and stable.

[0008] It is accordingly, an object of the present invention to providea masonry building block which does not require mortar and can beassembled to form a stable wall or other such structure having amonolithic appearance.

[0009] (2) Description of Related Art

[0010] Applicant is aware of no prior art directly relevant to thepresent invention. In the Office Action of Mar. 24, 2004, four priorU.S. patents were cited: U.S. Pat. No. 5,881,524, No. 4,794,749, No.5,379,562 and No. 6,204,0688.

BRIEF SUMMARY OF THE INVENTION

[0011] In accordance with the present invention, a building block has arecessed grout trough at its mid-perimeter, top, bottom and ends. Italso has a horizontal hollow core and beveled edges. The block can belaid dry without mortar. After each row of block has been positioned aliquid grout is poured into the grout trough at the end of each block.

[0012] It flows down the end trough into the bottom trough. The groutsets up quickly and firmly adheres each block to the adjacent block. Theassembled block present a monolithic surface with no mortar joints.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0013]FIG. 1 is an elevation view of the top of a standard in-line block

[0014]FIG. 2 is an elevation view of the left side of the block shown inFIG. 1

[0015]FIG. 3 is an elevation view of the right side of the block shownin FIG. 1

[0016]FIG. 4 is an elevation view of the front of a standard in-lineblock

[0017]FIG. 5 is an elevation view of the left side of the block shown inFIG. 4

[0018]FIG. 6 is an elevation view of the right side of the block shownin FIG. 4

[0019]FIG. 7 is an elevation view of the top of a corner block

[0020]FIG. 8 is an elevation view of the left side of the block shown inFIG. 7

[0021]FIG. 9 is an elevation view of the right side of the block shownin FIG. 7

[0022]FIG. 10 is an elevation view of the front of a corner block

[0023]FIG. 11 is an elevation view of the left side of the block shownin FIG. 10

[0024]FIG. 12 is an elevation view of the right side of the block shownin FIG. 10

[0025]FIG. 13 is an elevation view of the top of a foundation wall laidwith the grout block

[0026]FIG. 14 is an elevation view of the front of a foundation wall inFIG. 13

DETAILED DESCRIPTION OF THE DRAWINGS

[0027] Reference will now be made to the preferred embodiment of theinvention as illustrated in the accompanying drawings.

[0028] The standard in-line block 1, is illustrated in FIG. 1 through 6.It has an inner revetment 2, which extends around its inner periphery.It has an outer revetment 3, which extends around its outer periphery.The “outer periphery” refers to that side of the block which forms theouter surface of a wall, the surface which is generally visible.

[0029] A top trough 4 is formed between top revetments 2 and 3. Sidetrough 5 is similarly formed between side revetments 2 and 3. A bottomtrough 6 is formed between bottom revetments 2 and 3. The block 1 has anouter face surface 8. There is a beveled edge 7 on the outer revetment3, which frames the face surface 8.

[0030] The corner block 10 is illustrated in FIG. 7 through FIG. 12. Ithas an inner revetment 12, which extends around its inner periphery. Ithas an outer revetment 13, which extends around its outer periphery.

[0031] A top trough 14 is formed between top revetments 12 and 13. Sidetrough 15 is similarly formed between side revetments 12 and 13. Abottom trough 16 is formed between bottom revetments 12 and 13. Theblock 1 has outer face surfaces 18 and 19. There is a beveled edge 17 onthe outer revetment 13, which frames the faces surfaces 18 and 19.

[0032] The inner revetment 12 has a gap 11, which is the same width astrough 14 (i.e., eight inches). Gap 11, functions as an opening totrough 14. When the corner block 10 is laid in a course of blocks, ithas a standard block 1, next to it and in line with it on one end.

[0033] The inner revetment 12 has a gap 11, which is the same width astrough 14 (i.e. eight inches). Gap 11 functions as an opening to trough14. When the corner block 10 is laid in a course of blocks, it has astandard block 1, next to it and in line with it on one end. It hasanother standard block 1, perpendicular to its other end. The top trough4 of the standard block 1 in line with the corner block 10, iscontiguous with the top trough 14 of corner block 10. The top trough 4of the standard block 1, perpendicular to corner block 10, is contiguouswith gap 11.

[0034] Although not specifically illustrated in the drawings, it shouldbe understood that the bottom side of corner block 10 is the same as thetop side, in that it has a gap in the inner revetment making bottomtrough 6, contiguous with bottom trough 16. Therefore, the same cornerblock used in a left-hand corner is simply inverted to use in aright-hand corner.

[0035] It will be appreciated from the structure as described above,that (as illustrated in FIG. 13) the contiguity of the top trough 4, andtop trough 14 (with gap 11) provides an unimpeded trough around theentire perimeter of the wall. It should also be understood that thebottom surface of each block 1 and block 10, is identical to its topsurface. So each is invertible. As illustrated in FIG. 14 when a courseof block 21 is placed over the course 22 immediately beneath it, the toptroughs 4 and 14 of the course 22 align with the bottom troughs 6 and 16of course 21. So the troughs 4 and 14, covered with troughs 6 and 16,form an unimpeded channel which extends around the entire perimeter ofthe wall.

[0036] The standard block has a cavity 9 formed through its middle. Thecorner block 10, has a similar cavity 20 formed through most of itsmiddle but terminating short of the end face surface 19. The purpose ofcavities 9 and 20 is to make the blocks lighter in weight and betterinsulating. The cavities 9 and 20 are filled with light weightinsulating material such as plastic foam.

[0037] One development, which makes the present invention possible andpractical, is recently available non-shrink grouts, which are of lowviscosity and readily pourable.

[0038] After the course 21 of blocks 1 and 10 has been laid, lowviscosity grout is poured into side troughs 5 and 15 up to and even withthe top troughs 4 and 14. The grout being only slightly thicker thanwater, quickly flows down the side troughs 5 and 15, and then into theunimpeded channel formed by the confluence of troughs 4 and 14 withtroughs 6 and 16 which extends around the perimeter of the wall. Thegrout does not flow into cavities 9 and 20 because they are filled withplastic foam or other insulation material. In an alternative form of theinvention, where cavities 9 and 20 are not filled with insulation, theopening ends of cavities 9 and 30 are covered with caps of light weightinexpensive material like cardboard or plastic sheet, so that the groutdoes not flow into cavities 9 and 20. The grout will flow into thetiniest crevices and when hardened will completely seal and bond theblocks together. The next course of blocks is then laid with verticaljoints falling at mid-block of the course below and the process isrepeated up to the top of the wall in a pattern similar to conventionalblock laying. Reinforcement bars of metal may be placed in the troughsbefore grout is poured to further strengthen the wall.

What is claimed is:
 1. (Original-cancelled) The recessed grout trougharound the mid perimeter of the grout block.
 2. (Original-cancelled) Thehollow horizontal cavity through the center of grout block. 3.(Original-cancelled) The beveled edges on the front and back faces ofgrout block (see drawings).
 4. A block wall construction comprising: aplurality of in-line blocks, each of said blocks having an inner facesurface, an outer face surface and an exterior perimeter surfaceextending between said face surfaces. revetments formed on the inner andouter edges of said exterior perimeter recessed grout troughs formedbetween said revetments said in-line blocks laid in courses betweencorner blocks said corner blocks have an inner face surface, an outerface surface, and an end face surface extending perpendicularly betweenone end of said inner face surface and the corresponding end of saidouter face surface each of said corner blocks having an exteriorperimeter surface extending between said face surfaces revetments formedon the inner and outer edges of said exterior perimeter a recessed grouttrough formed between said revetments a gap formed in the revetment onthe inner edge of the exterior perimeter said gap being contiguous withthe grout trough of the in-line block adjacent thereto
 5. An in-linebuilding block comprising: an inner surface, an outer face surface, andan exterior perimeter surface extending between said face surfacesrevetments formed on the inner and outer edges of said exteriorperimeter recessed grout troughs formed between said revetments and notvisible on said surfaces
 6. A corner building block comprising: an innerface surface, an outer face surface, and an end face surface extendingperpendicularly between one end of said inner face surface and thecorresponding end of said outer face surface said corner block having anexterior perimeter surface extending between said face surfacesrevetments formed on the inner and outer edges of said exteriorperimeter accessed grout trough formed between said revetments a gapformed in the revetment on the inner edge of the exterior perimeter 7.The block of claim 5, having a hollow core
 8. The block of claim 7,wherein said hollow core is filled with light weight insulation material9. The block of claim 8, wherein said insulation material is plasticfoam
 10. The block of claim 7, wherein each end if the hollow core iscovered with a cap to prevent poured grout from entering said hollowcore.
 11. The block of claim 5, wherein the outer face surface has abeveled edge around its periphery
 12. The corner block of claim 6,wherein the outer face surface and the end face surface have bevelededges around their periphery
 13. The corner block of claim 6, having apartial hollow core, open on one side but closed from the end facesurface side
 14. The corner block of claim 13, wherein said hollow coreis filled with light weight insulation
 15. The block of claim 14,wherein said insulation material is plastic foam
 16. Currently amended)The block of claim 7, wherein the open end of the hollow core is coveredwith a cap to prevent poured grout from entering said hollow core